Mold apparatus for casting metals



July 5, 1949. c. WESSEL 7 2,474,963

' MOLD APPARATUS FOR CASTING METALS Filed June 21, 1945 3 Sheets-Sheet l 7 z 4% 2a 93 /0.9 "B1 July 5, 1949.

(.7. WESSEL MOLD APPARATUS FOR CASTING METALS 3 Sheets-Sheet 2 Filed June 21, 1945 July 5, 1949. c. WESSI'EL 2,474,963

MOLD APPARATUS FOR CASTING METALS Filed June 21, 1945 3 Shets-Sheet 3 Patented July 5, 1949 MOLD APPARATUS FOR CASTING METALS Carl Wessel, Chicago, Ill.

Application June 21, 1945, Serial No. 600,719

8 Claims.

The present invention relates to mold apparatus for casting metals, and is particularly concerned With apparatus which constitutes a marked improvement over that disclosed in the prior patent to C. H. Bierbaum No. 1,138,443, Apparatus for producing castings, patented May 4, 1915.

One of the objects of the invention is the provision of a casting apparatus of the Bierbaum type, from which the disadvantages which are inherent in that and other prior art devices have been eliminated and which is adapted to produce castings of complex and intricate form, which are absolutely sound, nonporous, free from aggregations, impurities, or nonhomogeneous characteristics, and having an improved crystalline structure.

Another object of the invention is the provision of improved methods of making castings which are adapted to be of the character described, with a minimum of labor and with the expenditure of a minimum amount of time so that the castings may be produced in a quality and by What might be called mass production methods.

Another object of the invention is th provision of improved castings having homogeneous, sound body with improved crystalline structure and of various complex and intricate shapes that could not be made by any of the methods of the prior art.

Another object of the invention is the provision of apparatus and methods of casting which are so radically different in structure, operation, and method, and which are based upon the development and reconstruction of devices of the art prior to all of my previous inventions so that the present apparatus and methods have no relation or dependence, nor do they constitute improvements of my prior inventions.

Another object of the invention is the provision of improved apparatus and methods which are equally adaptable to use for all kinds of metals, and by means of which the perfect filling of the mold and the casting of substantially perfect counterparts of the pattern are practically assured for each operation so that there will be a minimum number of rejects.

Other objects and advantages of the invention will be apparent from the following description and the accompanying drawings, in which similar characters of reference indicate similar parts throughout the several views.

Referring to the drawings, of which there are three sheets,

Fig. 1 is a side elevational view of a casting apparatus embodying my invention, certain parts of the apparatus being omitted from the right side of the drawing by reason of lack of space;

Fig. 2 is a top plan view of the apparatus, the mold being shown closed, in full lines, and open in dotted lines;

Fig. 3 is a fragmentary elevational view of the lower part of the machine of Fig. 1, which includes those elements that Were omitted from Fig. 1 by reason of lack of space;

Fig. 4 is a view in perspective of the particular form of casting which may be made by means of the mold, which is included in the apparatus that has been chosen to illustrate the invention;

Fig. 5 is a view in perspective of the mold shown apart from the special form of ladle with which it is used;

Fig. 6 is a fragmentary top plan view showing the form of universal connection between the removable core and the threaded member that is used to withdraw or insert it;

Fig. 7 is a fragmentary vertical sectional view taken on the plane of the line 1---'! of Fig. 1, looking in the direction of the arrows, showing the structure of the mold in closed position and that part of the casting in the mold which appears at this plane;

Fig. 8 is a vertical sectional view, taken on a plane passing through the axis of the mold and th tilting ladle to which the mold is connected, showing the arrangement of the mold with respect to the supply of metal in the ladle prior to the formation of a casting.

Fig. 9 is a similar fragmentary view showing the position of the metal in the mold and ladle during the pouring of a casting;

Fig. -10 is a fragmentary sectional View showing the appearance of the casting in the mold after the pouring operation and after congelation, but before removal'of th casting from the mold;

Figure 11 is a fragmentary view taken on the plane of the line I l--| l of Figure 9.

Referring to Figs. 1 and 2, indicates in its entirety the casting'apparatus, which includes a tilting ladle 2| and a suitable mold 22 directly connected to the ladle and having its filling opening registering with and communicating with the discharge opening of the ladle 2 I.

The ladle 2| is supported for tilting movement upon a frame 23, which may comprise a pair of similar standards 24 of the type shown inlj g. 1. These standards may be made of angle which is assembled of a plurality of piec shown, and welded together. For example, each standard 24 has an angle iron base 25, the hori- 53 and to a top plate 54.

3 zontal flange 26 of which engages the floor, and the vertical flange 21 of which is mitered to a suitable angle so that the juncture 28 between this flange and the similar flange on the upwardly extending frame members 29 and 30 may be welded together,

The upwardly extending frame members 29 and 39 preferably extend diagonally inward and upward from the ends of the base member 25, but are bent at 3| to extend vertically so that the upper parallel portions may be joined by a horizontal angle iron frame member 32, which is welded in place.

The two standards 24 which form the frame 23 are joined below the ladle 2| by angle irons 34, 35, the ends of which are welded to the upwardly extending frame members 2 9, 30 on each standard and by tie bolts 36 which bind the two frame members together by means of nuts 3'1.

Additional tie bolts 38 and braces 33 assure the absolute rigidity of the frame 23. The horizontal frame member 32 carries a vertically extending flange 46 which is provided with a horizontally extending bearing 4| for rotatably supporting the trunnions 42 of the ladle.

The trunnions 42 comprise stub shafts carried by the trunnion plate 43, which in turn is adjustably mounted by means of a plurality of screw bolts 44 on the channelled members 45, 46, which are secured to the ladle 2|. bers 45, 46 have their projecting flanges of suitable length and shape to engage the cylindrical shell 41 of the ladle 2| at the point at which these channels are located, so that they can be welded to the shell.

The channelled members 45, 46 are provided with a plurality of threaded bores 48 located at equally spaced points, so that the trunnion plate 43 may be shifted upward or downward to change the balance of the ladle 2|, depending upon the amount of metal which is to be used or depending upon the weight, structure, and location of the mold.

Each trunnion 42 is preferably provided with a thrust bearing member 49 having a bore for fitting the trunnion and having a radially extending flange 59 for engaging the end of the hearing. The thrust collar 49 is secured in place by the set screw 5 I.

The ladle 2| preferably consists of a substantially cylindrical metal shell, the cylindrical portion of which is indicated by the numeral 52, this portion being welded to a heavier bottom plate The top plate 54 is provided at one side, such as the right side (Fig. 8) with a substantially rectangular slot 55, forming a filling aperture; and this aperture may be closed by means of a cover member 56 having a substantially flat upper body 5! and a cylindrical side flange 58, the cylindrical side flange being formed on a radius slightly larger than that of the side wall 52 so that it may overlap the side wall, which is also formed with a slot 59 at that corner communicating with the slot to form a suitable aperture in the corner of the ladle shell.

The ladle is lined on its bottom, sides, and top with a heat resistant and heat insulating refractory lining 66 of substantial thickness, which is formed with a substantially cylindrical chamber 6|.

The cylindrical side wall of the refractory lining is indicated at 62, the bottom wall 63 and the top wall 64. At the upper right corner (Fig. 8) where the metal shell has an opening, the refractory lining 64 also has an opening which The channelled mem- 4 is defined by a pair of flat side walls 65, an upper wall 66 at the end of the lining top 64, and the horizontal wall 6! at the top of the side wall 62 of the refractory.

The angular cover 56 is filled with a block of refractory 68, which is triangular in cross section, and which is anchored to the cover 56 by suitable anchoring devices (not shown) and which overlaps the beveled surfaces 69 on the refractory lining 60 of the ladle surrounding the filling aperture.

The cover may be provided with any suitable form of handle 19, such as a large eye that can be engaged by a hook, and which is riveted in the wall 58 of the cover. The opposite edge of the cover plate 51 is formed with a hinge 1|, which has a hinge plate 12 riveted or welded to the top plate 54 and is provided with a pintle 13.

Thus the cover provides a fairly tight closure for the chamber 6 but permits a limited amount of leakage; and it may be opened and laid over on the top plate 54 whenever it is desired to skim the metal in the ladle or to observe it or flux it or add to the charge.

The bottom wall 63 of the refractory lining 69 is formed with an upstanding pedestal 14 having a. plane upper surface 15 which is of substantially the same size as the bottom 16 of the crucible 17, which is intended to be used in the ladle.

The crucible 11 may be made of any suitable refractory which is capable of withstandin the high temperatures to which the metal is to be subjected, and various compositions may be utilized for the crucible for the purpose of making sure that the metal is kept clean or for other effects upon the metal by the crucible.

Crucibles which may be purchased upon the open market may thus be embodied in the present ladle. The crucible 11 is smaller than the chamber 6|, leaving an annular space 18 around the crucible for the projection of a heating flame.

At its upper edge the crucible T! is preferably provided with an outwardly beveled surface '19 on its side, forming a sharp corner which may be anchored in the adjacent refractory 64 of the top wall, which closes the upper end of the crucible except for the following openings.

At the upper right corner a slot has been cut in the side wall of the crucible, the bottom of the slot being indicated at 8| and the sides at 82, this slot coinciding with the adjacent walls 65 and 6! of the opening in the refractory walls 64 and 62. This is the filling opening for the crucible, and the annular heating space 78 is isolated from it by an auxiliary bottom wall 83 extending from the crucible to the side wall 62 and having its upper surface flush with the surfaces BI and 61.

The member 83 may be a trough of substantially rectangular shape, the side wall of which extends upward and has its inner surfaces flush with the surfaces 65 and 82 on the refractory lining 62 and crucible 11.

This prevents any metal from falling down in the annular space 18, but there is still an open space between the walls 65 above the trough member 83 so that the gases of combustion and flame in the space 18 may have access from that space to the opening 82 into the crucible l1 and thence to the discharge opening and mold.

At the opposite side the crucible 11 is preferably formed with a round opening 84, which communicates with a short refractory conduit 85 of cylindrical shape that closes off the annular space 18 from this outlet.

' The conduit :85 communicates with a cylindrica'l opening '86 in therefractoryrside wall '62 which leads "to .a registering opening of the same size in the shell wall 52. This is therdischarge opening from the ladlelleadingctorthe mold, .and it may be of various sizes andshapes; but it is preferably of generous size so .that as the :metal runs along its bottom into the mold the air or other gases may pass backward into the crucible :chamber.

The metal shell 52 of the la'dl'eis provided with an aperture registering with'a bore 81 in the refractory wall 62 for receiving the burner nozzle -88, which is connected to suitable conduits 89 fastened by brackets to the ladle, and which are in connection with a flexible hose :90 leading to sources of air and combustible gas, suchas illuminating gas, so that the burner may beoperated while it is being tilted. The burner 88 projects the flame tangentially around the crucible. .The burner nozzle 88 is smaller than the bore 81 "so that additional air for combustion is drawn in through the bore 81, although the nozzle :88 is already supplied with air and combustible .gas mixed in suitable proportion for efficient combustion. The gas and air are under a suitable compression as supplied. to the nozzle 88 so that these elements are provided at suitable pressure and in suitable volume to provide a very .hot flame which is projected "into the space 18 surrounding the crucible TI, and which penetrates over into the crucible above the trough 83 and into the discharge openings '84, 85, 88. This provides a neutral atmosphere in the crucible chamber above the molten metal '9I, and part of the gas of combustion escapes through the ladledis- "charge opening, whichisle'ft Wide-open, while the apparatus is being preheated by the flame, preliminary toits operation.

When it is being operated, the flame from the burner '38 may likewise 'be used to supplement the heat which is brought into the crucible by superheated batches of metal from a separate furnace to maintain theitemperatureof 'themetal ill ata temperature near to .themelting point so that casting may be accomplished under uniform temperature conditions.

In some embodiments of 'the invention the source of heat 88 may be :a fuel oil burner of suitable construction, by means of which fuel oil is atomized and supplied withairat suitableapressure.

The metal shell .521of1the ladle lis providedadjacent the discharge opening 86 with an enlarged opening -92, which also :extends through a mold-supporting plate 93 so that the refractory may extend through these :openings in the form of a collar into engagement with :the moldplate 94, which supports the various :partsof the mold as a unit.

The mold-supporting :plate 93 may consist of a substantially rectangular plate that is secured directly against the side of the shell 52 and is braced and secured in place by means of angle irons .95, 96, which may be riveted or welded to the plate 93 and to the shell 152. The plate 93 has :a plurality of through bores, which may be threaded to receive a plurality of screw bolts passing through bores-inithe p1atei94an'd threaded into plate 93 to secure the .mold unit on the ladle unit, withthe filling-and discharge openings'in registry.

Various types Of molds may -.be attached to the ladle described ffor making castings ;of different shapes; but in ,general it :is "found that most molds (requireconsiderableldevelopment and adaptation, and their iCDIlStI'llIifiOII must :be e- .culia-rly adapted for ease with the present iadles in order to secure good results. 'Themolds and all of the metal parts 20f the ladle previously described may be made out of steel, the molds in particular being made rout .of .amild :steel which is suitable for this purpose on account of its worlting qualities.

However, in some embodiments of the inventionsand molds, plaster of Paris molds, and any other types of molds known to the prior art may he employed; but if the moldsare made of sand or plaster of Paris or aother'nondurable material, their parts are preferably supported in metal shells.

Referring to Fig. '4, this view shows in perspective acasti-ng Hill, which maybe made by means 'of the present apparatus. It consists of a substantially cylindrical -bod-y -'I 0 I having a centrally located cylindrical stem I'02 extending from its closed end.

"Ihebody -I BI is hollow, having a relatively large concentric bore I03, and it is provided with apair of substantially circular ports I04, I05 located in the body wall -I-0I diametrically opposite to each 'other. The ports I84, I05 are each provided with one or more transversely *located curved bars I06, I-Il'I, the bars being pf substantially rectangular cross section and of the same thickness as the wall I08 of the body-and provided with outer surfaces which are partially cylindrical and formed by elements "of the same cylinder forming the body I'll-I.

The bore 10-3 has a slight taperso as to permit thewithdrawal-of the 'core 'IIl9 by means of which *this bore-is formed.

Referring now to 5, the main parts ofthe mold comprise the supporting plate '94, the two mold halves III] and "HI, the central core I09, and a pairofsidecores I I2, H3.

Each-of the mold :halves ,I I0, 'I I! may consist of a block of metal, such as steel, having ,plane rectangularsides, one-of these sides being formed with 'a half of the mold cavity. 'Eachblock H0, -I'II is preferably "built up of a plurality of sections or smaller blocks which are secured together and held in alignment by steel dowel pins in accurately located bores.

The cavities formed in the two blocks may be identical, as theypresent casting is symmetrical; and each cavity may comprise one-half of the cavity necessary to form "the complete article.

In the present casting the mold is provided with a frusto-conical or funnel-shaped filling opening -II I leading to a cylindrical bore H5, which forms the stem I02. The cylindrical 'bore -I I'5 communicates with the enlarged bore IIB, which forms the cylindrical body I EI-I of the casting; and the bore -I'I6 communicates with a smaller bore It! for receiving and guiding the central core N19, to which bore Ill is substantially complementary.

Thus each of the mold halves IIO, II I is formed with a cavity capable of providing the space 'forone-hal'f of thebores -I I4 to II I, these ha'lf cavities registering with each other when the mold is closed.

In addition to this,each mold block IIB, III is provided with a through bore -I-I8, the bores 'beinglocatecl to'receive'thecores H2, H3 (Fig. I?) which form the circular apertures I05 and form the :partially cylindrical bars 106, I01 of the casting.

The.side scores H2, il [3 eachcomprise a sub- .stantially cylindrical Ebody which is provided with in the cylindrical member a cylindrical enlargement H9, the cylindrical enlargement having a thrust surface I20 which engages the side of each mold block to limit the inward movement of the cores H2, H3.

The cores H2, H3 are provided with a partially cylindrical inner surface I2I which engages the central core I09 and is complementary thereto, for forming the circular apertures I04, I05; but this cylindrical surface I2I is formed with a pair of transverse rectangular grooves open at each end to communicate with the space for the side wall I08 so as to form the transverse bars I06, I01 of th casting.

It is necessary that such cores as the side cores H2, I I3 be definitely held in a proper rotative position; and therefore each head I I9 is provided with a pair of dowel pins, such as, for example, dowel pin I22, which is received in a short socket I23 in each block, and also the dowel pin I24 which may be secured in the socket I25 in each mold block, but may slide in an aperture I26 H9 of each core I I2, H3.

The cores I I2, I I3 are preferably provided with a form of force multiplying means for retracting them; but, as these cores are not located deeply in the casting, it is sufficient to provide a bellcrank lever I21, the longer arm I28 of which serves as a handle, and the short arm I29 of which has a bore for receiving a screw bolt I30 that is threaded into the head H9 of each core.

The bellcranks I21 are each pivoted on a suitable bracket I3I carried by the mold block so that a pull on the handle I28 is sufiicient to retract the cores H2, H3 from the apertures I04, I05 of the casting. The central core I09 is likewise preferably provided with a cylindrical head I3I, having an annular thrust surface I32, which engages the plane end I33 of the mold assembly, to determine the position of the core I09 in the assembly and to make the end wall of the casting of definite thickness,

This core is also provided with force multiplying means for retracting it, which is preferably in the form of a screw shaft I33, which is carried by a threaded bore I34 located in a supporting plate I35.

The core I09 and its operating mechanism are preferably permanently attached to the block H so as to move with it; and for this purpose the block H0 may have a pair of cross bars I36, I31 bolted or welded to it. The cross bars I36 support at their ends four bolts I38, which may be surrounded by tubular spacers so that when the bolts are threaded home in the bars I36, I31 the tubular spacers space the plate I35 from the bars I36 and hold it parallel to the end surface I33 of the mold assembly.

Referring to Fig. 6, the screw shaft I33 is preferably provided with a reduced threaded end portion I39 that passes through an enlarged bore I46 in a partially spherical cup MI. The reduced threaded portion I39 is provided with a nut and lock nut I42, which are located with a clearance with respect to the annular shoulder I43 so that there is a limited universal joint between the screw shaft I33 and the cup MI.

The cup MI is fixedly secured by means of a plurality of screw bolts I44 to the head I3I of the central core, the bolts passing through the attaching flange of the cup and being threaded into the head so that the core I09 may have a limited universal movement; and as seen in Fig. the core I09 has moved out of the half bore H1.

When the mold halves are assembled, however,

the core I09 has a sliding fit in the bore H1. At its left end the screw shaft I33 carries a cross bar I45, serving as a handle for rotating the shaft I33. The handle I45 is secured in a slot in the shaft I33 by the screw bolt I46. The two mold halves H0, III comprise block assembles of equal length, each of which is provided with a plane end surface I41. When the mold is closed, these plane end surfaces I41 are in the same plane, and the funnel-shaped opening H4 registers with the opening I48 in the plate 93 and with the opening I49 in the plate 94.

It is necessary for these mold halves to move in a particular manner to separate the mold from the casting and to separate the casting from the machine. For this purpose the plate 94 is provided with a pair of guide bars I50 and I5I mounted in parallel position on the plate 94 by means of a plurality of screw bolts or rivets I52 which pass through spacers I53 so that the mold halves H0, III may be guided at a point spaced from the plate 94.

The guide bars I50, I5I (Fig. '7) are provided with opposed slots I54, preferably rectangular in cross section and adapted to receive the upwardly and outwardly projecting reduced portions I55 of an actuating bar I56, which is carried by the right side of the mold half I I I.

The actuating bar I56 consists of a rectangular bar having six plane sides, the end surfaces of which slidably engage the opposed plane surfaces on the guide bars I50, I5I. The reduced portions I55 of the actuating bar I56 are slidably mounted in the rectangular slots I54 in the guide bars I50, I5I. At the same time the plane end I41 of the mold half I II slidably engages the outer surface of the plate 94.

Thus the mold half II I is mounted for sliding movement away from the point of registry with the opening I49 in the plate 94, but the end of the slot I54 acts as a stop for positioning this mold half in registry with half of the opening I49.

In order to move the mold half I I I, it is preferably provided with an outwardly projecting connecting rod I51, which may consist of a rectangular bar fixedly secured by a rivet in a complementary slot in the actuating bar I56. The end of the connecting rod I 51 is slotted and provided with registering bores for the pintle I53, which also passes through the hole in the handle lever I59.

The handle lever I59 is elongated at its upper end sufiiciently to provide a force multiplying action, and is shaped with a handle I60 at its upper end. At its lower end it is pivotally secured by means of a rivet I6I to a laterally projecting bar I62, which is fixedly secured to the plate 94 by a pair of rivets.

In order to compensate for the fixity of the connecting rod I51 in the actuating bar I56 the lever I59 has a slot I63 for the pintle I58. Thus a pull on the lever I59 is adapted to cause the mold half III to draw away from the casting in the mold from the full line position of Fig. '7 to the dotted line position in this view.

For the support of the other mold half H0 the guide bars I50 are provided with a pair of spacers I53 at the left end of each guide bar I50, I5I, and the aperture I64 between these spacers is adapted to receive the reduced cylindrical end I65 of the actuating bar I66 for the mold half I I0.

The actuating bar I66 is fixedly secured to the mold half H0 by rivets, bolts, or other fastening means, and this bar is provided with a partially cylindrical portion I61, which is curved on a aerator;

radius equal to the distance of the trunnion I65 from the plate 94 when the mold is assemble as shown in Fig. 10. i

The slot I64 larger than the trunnion I65 in order to provide'a clearance at this point so that the mold halves It'll; II I may be clamped together tightly with their inner plane surfaces I58 engaging each other-and so that they will not be restricted by' the trunnions I 65. In order to assure the alignment of the twomold halves the mold half HI is provided with a plurality of cylindrical bores I59 in its face I68 and the opposite mold half II'II is provided with projecting dowels llll engaging in the bores I59 and effecting a positive alignment of the mold halves.

In order toclamp the mold halves together, mold member III may be provided at its plane top and bottom surfaces III, I'I2- with upwardly and downwardly projecting pins I131 The other mold half III) may be provided with a pivoted lever I74 mounted upon a pin I and provided with a hook I16 having a curved camming surface Ill. The lever I'M may be actuated by an upwardly extending handle lit; and when the mold halves are assembled, the camming surface IIl may be pushed over the pin M3 to draw the molds tightly together.

Referring now to Fig. 3', the tilting ladle -2I is preferably provided with a laterally projecting bifurc-atedarm I99, the legs of which are located on the opposite sides of a connecting rod WI.- The connecting rod I8I carries a piston I 82;

which is slidably' mounted in a cylinder M3.

The cylinder 83 is fixedly mounted upon an extension I84 of the base member 25, and is provided with a conduit I8 5 having a throttling'valve I86, the conduit leading to the lower end of the cylinder.

The piston I82 is a one way piston having an upwardly extending cup leather I81 carried by a suitable cylindrical member I 88- and having a beveled edge I89 so that upon the upward movement of the piston air is. sucked into the base or" the cylinder I83, but upon the connecting rod being relieved of any thrust the piston and rod drop again by gravity. r

The connecting rod I8I is preferably cylindrical, and the piston preferably has an upwardly extending frame I90 provided with a centrally located guide member Iflih'aving a bore #92 for guiding the rod 'I'8I so that the rod IBI projects upward in a vertical direction.

The guide member I9! may be an elongated threaded member threaded into a bore I93 in the frame iti! so as to serve as an adjustable stop for determining the maximum amount of tilt of the ladle 2| in'a counterclockwise direction in Fig. 3. At its upper end the piston rod I8i is provided with a multiplicity of apertures I94 for receiving a through bolt I95 carrying a roller I96 on each side of the connecting rod I83 for engaging the two legs of the ladle-carried arm I 89. 7

Below the arm I89, when the piston I82 is in its lowermost position, and the'ladle 2! is level. the connecting rod I 5| is provided with additional apertures M4 for receiving another through bolt I9! provided with similar rollers I98 for engaging the lower side of the arms I89.

Thu thepiston Hi2, rod IBI, and lower rollers I38 serve as a stop to determine the range of movement of the ladle in a clockwise direction in Fig. 3 so as to make sure that the ladle will not tilt toward the right far enough for the metal to spill out of the aperture 61.

The rollers I98 also serve to insure the quick return of the pistonto its lowermost-position for the next casting operation; The multiplicityof aperture I96 servetopermit adjustment of the positions of the rollers I96" and I98 so that on the tilting of the ladle 2| the piston I82 does not come into play until the-mold has tilted to a predetermined'position; after which the piston and cylinder serve as a jackpot inabsorbing the shock or the tilting motion of the ladle and bringingthe ladle to a stop, and theyserve also to place 'a predetermined suction on predetermined parts of the mold" at the proper time to. remove the air from themold-and to perm-ita' perfect filli'n'goithe mold by metal. i The suction pipe I is connected through valve I36 to a flexible conduit or hose 19-9 which may be'arrnored or otherwise protected fromtheheat; and the hose is-provided with a metal 'fittingiilfi (Fig; 1"), which is threaded into the upper face of one of the mold sections, such as themol-d sectionllHFig. 1; Fig.- '7) i The fitting 209 extends into a threaded bore 2!; which may communicate with a longitudinally extendingbore 202, which is closed at each end, but which otherwise extends substantially through all of the sections or blocks of which each mold half is made.

"Referring to Fig; 5,'it will be seenthat the mold member H6 is made of four sections, indicated at .2ll3, 294, 205; 206-. These sections are indicated by the lines of division 201,168, 209."

"Referring now to-Fig. 11, this is a fragmentary view, showing one of the faces of one of these sections 2ts 2et; taken on-the plane of the line II'-Il of Fig. 9. Thisis exe plary of all of the faces of the various sections-which are incon tact with each other. Each of such section faces is provided with apartially circular groove conduit 2 III, which is preferably formed on the line of a circle so that it maybe cut in the block by means of a lathe.

The conduit 219 may be of any suitable size-to carry suilicient air; but is a relatively small con: duit communicating-with the conduit 262'leading to the hose I99, and has all of the similar circular conduits ZIII in the various facesof the mold half sections communicating" with the same bore 202. It will be evident that-the mold-has suitable circular conduits between each of the mold sections communicating with a source of suction. 1

The faces of the mold sections at the junctures 201, 2G8; and 269 are also formed with a multiplicity of radially extending fine grooves 2| I. These groovesmay be located-on one or both of the contacting faces, but'the grooves 2i I are sufficiently small so that while they will pass air', they will not pass the molten metal of which the casting isbeing made. Y 'I-hus all of the corners of the mold cavity areconnected'by means of these fine grooves 21! with suitable suction conduits leading back to the suction cylinder I83 so that by means of suitable adjustments suction can be applied to 'anyor all parts of the mold where air'may be entrapped.

The operation of the apparatus is substantially as follows: The mold is assembled with the ladle and placed in the open position, as shownin Fig. 5; and thecrucible-II of theladle isfirst preheated by means of the burner 88, the gases of combustion passing around thecrucible and up into the filling trough 83 and into the crucible and out of the discharge apertures 84, 85, 86 past the mold. which is also slightly preheated.

However, I' prefer'not-to rely upon the flame 11 for preheating the mold, but the preheating of the mold may be done by making a few castings, such as five or ten castings, preferably the latter, which castings are rejected, and melted upon the beginning of operations.

After the ladle has been preheated for a suitable length of time, the door 55 may be opened and a charge of metal may be poured into the crucible 11, this metal having been previously melted in a separate furnace; and the ladle is preferably provided with sufficient metal to make a multiplicity of castings. The temperature of the metal in the crucible of the ladle is maintained by continuing the operation of ti e flame from the burner 88 and also by supplying the ladle with additional batches of molten metal, which are superheated above the desired temperature so as to raise the temperature of the metal in the ladle crucible and maintain it at the temperature desired. The metal in the crucible of the ladle is fiuxed, if necessary, and carefully skimmed to make sure that it is absolutely clean and homogeneous and when it is in proper condition, from the point of view of cleanliness, temperature, etc., the casting operations may be begun.

The temperature at which casting is carried on is preferably quite close to the melting temperature for the metal which is being used, so that the casting may congeal quite quickly, and thus operations can be speeded up without delaying for the congelation and cooling of the castn s.

The mold should first be closed and the two mold halves secured together by means of the hooks I14. In order to do this, it is necessary to swing the mold half IIll around toward the observer in Fig. until the face Ml strikes the outer surface of the plate 94. Then the mold half I I I may be caused to slide on the guide bars I50, I5I by means of the handle I60, which is pushed inward until the actuating bar I56 reaches the end of the slots I54, where this mold half is in registry with the discharge opening of the ladle.

The two mold halves are then secured together by means of the hooks I14, which ca-m the two halves of the mold tightly together and secure them. The position of the trunnion I55 on the mold half III) is such that the bars I50, I5I hold this mold half tightly against the plate 94 by engagement of the bars I50, I5I with the trunnions I65 when this mold half HE is in the position at right angles to the plate 94.

Although the mass production of castings involves the melting of metal in a furnace other than the ladle which supports the mold, for small operations or for experimental operations involving the adjustment, correction, or adaptation of the mold, the metal may be melted in the crucible by the flame which is projected tangentially around the crucible.

The side cores H2, II 3 should then be shoved into place by moving the bellcranks I21 in the proper direction to move these cores into the mold. The central core I09 should then be driven in by turning the screw shaft I33 in a clockwise direction by means of the handle I 45 until the annular surface I32 strikes the outer face of the mold assembly. This leaves the core I89 spaced sufllciently from the end of the mold cavity to form the end wall of the casting I05 The dowel pins I10 in their sockets I59 will insure the two halves of the mold being in absolute registry. The side cores H2, H3 should 12 engage the central core I09 with those complementary end portions of the surfaces of the side cores which remain on either side of the grooves.

The machine is then in condition to start the making of a casting; and Figs. 8 and 9 illustrate the action of the apparatus at this time. In Fig. 8 it will be seen that the free surface of the molten metal 9I in the crucible I1 is below the discharge apertures 84, 86. The operator may then tilt the ladle by means of a suitable handle 2I2, the tilting action being in a counterclockwise direction in Fig. 8.

This causes the free surface of the molten metal to rise above the lowest part of the discharge aperture 84; and without splashing or agitation the molten metal will run down hill in the discharge aperture 86 into the mold cavity to the lowermost part of the mold cavity. The tilting motion should take place slowly and at a constantly increasing angle of tilt so that the molten metal flows continuously down hill into the mold cavity, which is filled without any splashing or separation into drops or segregation of any parts of metal which must be again remelted.

As the mold cavity fills from the bottom upward, the discharge aperture into the ladle is large enough so that the air from the mold cavity may pass back into the ladle above the free surface of the metal over the major portion of the filling operation of the mold. During this time that portion of the mold which is first filled begins to congeal first, but metal is constantly added above the congealing and most remote part of the mold, and the congealing progresses gradually upward from the bottom of the mold cavity toward the top and back to the metal in the ladle.

The present casting is merely exemplary of one form of casting which may have one or more uppermost portions of its cavity from which the air should be exhausted, such as, for example, the point 2I3 in the upper corner of the casting I00 (Fig. 4; Fig. 9). At a certain point in the filling of the mold the free surface of the metal in the mold and ladle will rise until it cuts off at the corner 2M (Fig. 9) the return of air from the mold to the ladle.

Just prior to this point the suction action of the piston I82 and cylinder I83 comes into play and the upper roller I96 on the connecting rod I BI is suitably adjusted to be engaged by the arm I at such a time. Thus before the air is cut off from returning to the ladle, the piston and cylinder I82, I 83 begin action and place a suction on the minute groove conduits 2I I in the faces of the sections of which the mold halves are constructed.

As certain of these grooves 2II are located to extend radially from the corner 2I3 in the mold cavity (Fig. 9), the air above the metal in this particular corner is no longer entrapped, but is gradually removed without any agitation or parts of the air being honey-combed into the casting.

The action of the source of suction is so coordinated with the flow of the metal into the mold from the ladle that the air is simply removed and the mold cavity is completely filled, and thereafter the filling continues by the molten metal running down hill into the cavity until it has filled that portion of the mold cavity that forms the stem I02 and extends into the funnelshaped opening II4, as shown in Fig. 18.

At this time the mold has been completely filled and, during its filling, congelation has been going on until the 'congelation extends backward into the funnel-shaped opening I I4, the free surface of the congealed portion being indicated at 2I5 (Fig. 10) At this time the piston I82 has reached its upper limit of movement, which is determined by adjustment of the threaded stop member I9I that also guides the piston rod IBI, and further tilting motion is arrested.

The air piston not only removes the air from the mold, but it acts like a dash pot to effectively cushion the end of the tilting of the mold so that there is a minimum amount of a tendency for the metal to be disturbed in the ladle.

The time required for tilting the mold is a matter to be determined by trial, and this time should be made as short as possible to expedite the making of castings; but it should be long enough so that the mold is filled by the continuous pouring without splashing and with a continuous filling of the mold from the bottom up ward to the filling opening.

In some cases it may be necessary to hold the ladle in the tilted position for a short time to give the casting time to congeal properly. This may also be determined by trial and by observation, and by the amount of sprue that is'left on the casting after the machine has been tilted back to the vertical position.

Assuming that the casting has congealed to the point 2I5, shown in Fig.- 10, the machine is then tilted back to the vertical position, this motion being limited by the lower roller I98, which also serves to return the piston to its lowermost position, aided by gravity and by the fact that the piston is a one way piston, producing suction only on the upward stroke.

Then the operator should immediately remove the cores, such as, for example, the central core I09, by screwing the screw shaft I33 in a counterclockwise direction until the core I09 reaches the position of Fig. 5. The two side cores H2, H3 should be withdrawn by rotating the bellcranks I21 in such direction as to pull these cores cut ward.

Then the hooks I14 should be unho'oked and moved to the position of Fig. 5 to release the mold halves from being held together, As the casting is intended to move with the mold half N0, the mold half III should first be separated from the casting by drawing outward on the hand I60, which causes this mold half to slide a from the casting.-

This sliding motion is s'uificient to move the mold half I I I far enough away so that this mold half does not interfere with the pivotal movement of the casting as it is held in the mold half III).

The casting is held in the mold half IID because the sprue, which may have parts of its wall extending into engagement with the plate 94, tends to hold the casting in the position in which it was cast. Thus the handle I60, which slides the mold half II I to the right in Fig. 5. leaves the casting with its sprue communicating with the filling opening and its body in the mold half I III. When the mold half III! is pivoted clockwise, looking from the top in Fig. 5, the location of handle I45 and length of the mold assembly is such that there is considerable leverage exerted about the pivot I64. This leverage will enable the operator to pull the sprue loose from the filling opening, the casting going with themold half I It in its pivotal movement. The handle I45 may then serve as a handle for causing the mold half H0 co-pivot in. a clockwise direction, looking at the top of Fig. 5, to draw the casting away from the plate 94, the casting being in the half cavity of the mold halt H0. The casting may then be grasped, so that it is promptly removed from the half cavity in the mold half I I0, which is preferably done by grasping it with tongs or other tools adjacent the exposed portion of the sprue forma-- tion so that there is no danger of marring any other part of the casting.

In order to assure the easy removal of the cast ing, the sprue should be kept within the funnelshap'ed portion H4 of the mold, but the conduit leading from this funnel-shaped portion into the ladle may be tapered inwardly so that if the some should be longer it will, nevertheless, be easily removable with the casting, due to this taper.

The slidable mounting for the pivoted members I 65 on the moldhalf I I0 also facilitates the easy removal of the casting from its position of Fig. 10' to that; of Fig. 5. The mold should then be closed at once and the cores put in proper place, and all parts properly secured, read for the makingof another casting.

The method of making castings with the present apparatus is briefly outlined as follows In order to assure a high degree of uniformity between the castings, the supply of metal should be kept uniform, and I propose to use a multiplicit y' of casting machines of the type shown in: connection with a single very large furnace, from which the batches of metal will be periodically taken in a molten condition.- As batches are taken outof the large furnace, additional metal will be added, which will, however, be small in proportion to the total mass of molten metal, and

' Will not vary its composition greatly.

The batches of superheated metal placed in the crucible of the present casting apparatus will tend to maintain the proper temperature for casting, and this may be supplemented by means of the flame, which keeps the apparatus at proper temperature.

In the making of a casting according to the present invention the use of any pressure whatever is preferably totally eliminated. I find it is not necessary to use any hydrostatic head of metal on top of the metal in the casting by means of the metal in the ladle, as it is not necessary to tilt the machine to this extent.

The machine need only be tilted sufiiciently to cause the metal to flow through the bottom part of the discharge opening, leaving the major portion of this opening free for the return of air. Then the metal runs down into the mold, filling it from the bottom, which is, of course, most remote from the filling opening of the mold; and as the mold is filled, there is always a portion of molten metal at the top of the metal in the mold, but the metal already deposited in the mold begins to be chilled and starts to oongeal from the bottom up as it is being filled.

Thus any shrinkage is automatically taken up by the fact that metal is being supplied from the top during the congealing.

The use of suction at a predetermined point during the tilting action does not involve the application of any pressure to the metal, but rather involves merely the removal of the air that may otherwise be entrapped in certain parts of the mold after filling has proceeded. to a point where molten metal isfilling up in the filling opening.

Where air isentrapped in a mold and pressure is applied, as in ordinary die casting methods and many of the methodsof the prior art, there is a tendency for the air to be forced into the metal in the form of bubbles and foam, producing a porous condition which may not be discernible from the outside of the casting.

This is totally eliminated by my method, which involves the removal of the air from the mold by a moderate suction at a proper time. The suction, which may also be applied to other parts of the mold that are already filled, produces no effect.

When it is necessary to pour a casting in such a way that two branches or parts which separate are being filled, the mold is Preferably arranged so that the metal will run down into both of them; and if these branches are again to join, it is so arranged that when, during the course of filling, these two branches of the casting join, they will both be in the molten condition so that a perfect molten junction will be formed.

During all of this time a neutral atmosphere is maintained above the metal in the ladle and leading to the mold by the flame, which has access to the space above the metal and to the mold cavity, and the products of combustion from this flame leak out through the cracks between the halves of the mold and through the cracks around the cover opening for the ladle.

A slight increased pressure is maintained in the ladle over that outside by this action, so that air is excluded.

The casting apparatus embodying the present invention occupies a. very small space when compared with the casting apparatus of the prior art for accomplishing the same purpose. It permits the use of a minimum amount of labor, and several hundred castings may be produced with a single machine having a mold with a single cavity in the course of a working day by one or two men.

The mold should, of course, be constantly kept in a clean condition, and with some metals it may be necessary to spray the inner surface of the mold with a separation compound, but with other metals it is not at all necessary.

The present apparatus may be constructed at a very low cost; and although molds made of steel are more expensive, the cost is readily absorbed in the cost of the many castings that can be made without deterioration of such a mold. As previously stated, any type of mold may be used with my apparatus and method, and the present mold is merely exemplary of one type of mold for carrying out the method.

While I have illustrated a preferred embodiment of my invention, many modifications may be made without departing from the spirit of the invention, and I do not wish to be limited to the precise details of construction set forth, but desire to avail myself of all changes within the scope of the appended claims.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent of the United States, is:

l. A mold for the casting of metals, comprising a supporting plate, said supporting plate having a filling aperture and a pair of mold members, each having substantially half of the cavity formed in it, one mold member being provided with a plane end surface engaging said plate, and with guide means for slidably supporting said mold member for sliding movement on said plate, away from the filling opening, the other mold member being mounted for pivotal movement on said plate in a direction away from the adjacent mold member whereby, after the casting has congealed, one mold member may be slid away from the casting and the other mold member may be pivoted outwardly, carrying the casting with it, away from the supporting plate, and a supporting frame carried by said other mold member and having a threaded bore and an axially extending core carried by a screw shaft in said bore and extending into a bore which forms a part of the cavity in said mold to form a tubular casting.

2. A mold for the casting of metals, comprising a supporting plate, said supporting plate having a filling aperture and a pair of mold members, each having substantially half of the cavity formed in it, one mold member being provided with a plane end surface engaging said plate, and with guide means for slidably supporting said mold member for sliding movement on said plate, away from the filling opening, the other mold member bein mounted for pivotal movement on said plate in a direction away from the adjacent mold member whereby, after the casting has congealed, one mold member may be slid away from the casting and the other mold member may be pivoted outwardly, carrying the casting with it, away from the supporting plate, and a supporting frame carried by said other mold member and having a threaded bore and an axially extending core carried by a screw shaft in said bore and extending into a bore which forms a part of the cavity in said mold to form a tubular asting, each of said mold halves being provided with a transversely extending bore and a sliding core in each of said transverse bores, said sliding cores being formed with partially cylindrical end surfaces engaging the first-mentioned axially extending core for forming apertures in the sides of said tubular member.

3. A mold for making a casting having a sprue, comprising a supporting plate provided with a filling opening of sufficient size to pass molten metal into the mold while the gases in the mold are passing out of the mold above the molten metal through said opening, and a pair of mold members movably mounted upon said supporting plate, each of said movable members being a metal member having a part of a mold cavity formed in it, one of said mold members being mounted for pivotal movement on the plate, and the other of said members being mounted for sliding movement on said plate, away from the first-mentioned mold member, whereby one half of the mold may be slid transversely on said plate to expose that portion of the casting that is formed by said half mold member, after which the casting and other mold member may be pivoted away from the plate to draw the sprue away from the filling openin of the plate, and securing means for holding said mold members together when they are engaging each other and engaging said plate, said mold members each be ing formed with a partially cylindrical groove providing a cylindrical bore when they are joined, and said bore having a slidable metal core located therein to form the casting with a bore in its end opposite to the filling opening, the said core being substantially cylindrical, and the mold members each being formed with an enlarged counterbore into which said core projects, and the core stopping short of the end of said counterbore, whereby the mold members and core form a cavity for a cylindrical cup-shaped member, and threaded means for Withdrawing said core from the mold.

4. A mold for making a casting having a sprue, comprising a supporting plate provided with a filling opening of sufficient size to pass molten metal intothe mold while the gases in the mold are passing out of the mold above the molten metal through said opening, and a pair of mold members movably mounted upon said supporting plate, each of said movable members being a metal member having a part of a mold cavity formed in it, one of said mold members being mounted for pivotal movement on the plate, and the other of said members being mounted for sliding movement on said plate, away from the first-mentioned mold member, whereby one half of the mold may be slid transversely on said plate to expose that portion of the casting that is formed by said half mold member, after which the casting and other mold member may be pivoted away from the plate to draw the sprue away from the filling opening of the plate, and securing means for holding said mold members together when they are engaging each other and engaging said plate, said mold members each be ing formed with a partially cylindrical groove providing a cylindrical bore when they are joined, and said bore having a slidable metal core located therein to form the casting with a bore in its end opposite to the filling opening, the said core being substantially cylindrical, and the mold members each being formed with an enlarged counterbore into which said core projects, and the core stopping short of the end of said counterbore, whereby the mold members and core form a cavity for a cylindrical cup-shaped member, and threaded means for withdrawing said core from the mold, said mold being provided with a cross head and a threaded member for engagme; said threaded means.

5. A mold for making a casting having a sprue, comprising a supporting plate provided with a filling opening of sufiicient size to pass molten metal into the mold while the gases in the mold are passing out of the mold above the molten metal through said opening, and a pair of mold members movably mounted upon said supporting plate, each of said movable members being a metal member having a part of a mold cavity formed in it, one of said mold members being mounted for pivotal movement on the plate, and the other of said members being mounted for sliding movement on said plate, away from the firstmentioned mold member, whereby one half of the mold may be slid transversely on said plate to expose that portion of the casting that is formed by said half mold member, after which the casting and other mold member may be pivoted away from the plate to draw the sprue away from the filling opening of the plate, and securing means for holding said mold members together when they are engaging each other and engaging said plate, said mold members each being formed with a partially cylindrical groove providing a cylindrical bore when they are joined, and said bore having a slidable metal core located therein to form the casting with a bore in its end opposite to the filling opening, the said core being substantially cylindrical, and the mold members each being formed with an enlarged counterbore into which said core projects, and the core stopping short of the end of said counterbore, whereby the mold members and core form a cavity for a cylindrical cup-shaped member, and threaded means for withdrawing said core from the mold, said mold being provided with a cross head and a threaded member for engaging said threaded means, said threaded means having a limited universal connection to the end of said core.

6. A mold for making a casting having a sprue,

comprising a. supporting plate provided with a filling opening of sufiicient size to pass molten metal into the mold while the gases in the mold are passing out of the mold above the molten metal through said opening, and a pair oi mold members movably mounted upon said supporting plate, each of said movable members being a metal member having a part of a mold cavity formed in it, one of said mold members being mounted for pivotal movement on the plate, and the other of said members being mounted for sliding movement on said plate, away from the first-mentioned mold member, whereby one half of the mold may be slid transversely on said plate to expose that portion of the casting that is formed by said half mold member, after which the casting and other mold member may be pivoted away from the plate to draw the sprue away from the filling opening of the plate, and securing means for holding said mold members together when they are engaging each other and engaging said plate, said mold members each being formed with a partially cylindrical groove providing a cylindrical bore when they are joined, and said bore having a slidable metal core located therein to form the casting with a bore in its end opposite to the filling opening, the said core being substantially cylindrical, and the mold members each being formed with an enlarged counterbore into which said core projects, and the core stopping short of the end of said counterbore, whereby the mold members and core form a cavity for -a cylindrical cup-shaped member, one of said mold members being formed with a transversely extending bore, and a core mounted in said latter bore and movable into engagement with the first-mentioned core to form the cup-shaped casting, with a lateral aperture.

7. A mold for making a casting having a sprue, comprising a supporting plate provided with a filling opening of sufficient size to pass molten metal into the mold while the gases in the mold are passing out of the mold above the molten metal through said opening, and a pair of mold members movably mounted upon said supporting plate, each of said movable members being a metal member having a part of a mold cavity formed in it, one of said mold members being mounted for pivotal movement on the plate, and the other of said members being mounted for sliding movement on said plate, away from the first-mentioned mold member, whereby one half of the mold may be slid transversel on said plate to expose that portion of the casting that is formed by said half mold member, after which the casting and other mold member may be pivoted away from the plate to draw the sprue away from the filling opening of the plate, and securing means for holding said mold members together when they are engaging each other and engaging said plate, said mold members each being formed with a partially cylindrical groove providing a cylindrical bore when they are joined, and said bore having a slidable metal core located therein to form the casting with a bore in its end opposite to the filling opening, the said core being substantially cylindrical, and the mold members each being formed with an enlarged counterbore into which said core projects, and the core stopping short of the end of said counterbore, whereby the mold members and core form a cavity for a cylindrical cup-shaped member, one of said mold members being formed with a transversely extending bore and a core mounted gamma in said latter nhorerand movablesintc engagement :With the first-mentioned core :to form *the acupr shaped casting, with a. lateral :a'pert'ure, :said slatfcer :core being :formed .With? azpartially icylindrical end surface forengaging=th ffirst mentioned1core -1 and having 1 a :pair :of grooves in said end surface whereby :the aperture :ha-s ia. "pair of transverse 'barszextendingiacross it.

8. Inaimoldzmr icastingmetals, the combination of a supporting zlplate with :a frame carried by said .plateehmit :a1fi11ing aperture inzthe plate,- said frame .having a pair 10f vertically :aligned apertures :at :on .end and :a :pair :of aligned slots at the other end, a pair of mold members, each having on its iinner side a :portion "of a cavity for the casting, one :of said mold members having'tnmni'ons mounted insa'id'ipair Dfapertures, and the ether of ssaid mold members having :guides-mountedinqsaid s1ots,:ac'tuating means for nausing one of :said mold members to slide, :the

:other of :said mold members being .pivotally mounted ato move-fits cavity :side away from {said plate, a supporting irame carried by the pivoted .mold :member, force multiplying means comprising a. screw mounted 1011 said frame, -and1a ;core 'connected ito said screw extending longitudinally into said cavities to be retracted by .said a-force multiplying ameans, amearis for holding 720 :said mold members 2m engagement with each other about :said more, :and a :pair -,of additional cores, acne Zbeingmounteddn eaeh mold member for engagement with the first-mentioned core, and means :for retracting the additional core members.

CARL WESSEL.

REFERENCES CITED The following referenlces are of record in the "file -0f this patent:

UNITED STATES PATENTS Number Name Date 732,966 Schinhari Ju1y"7,"1903 "1,466,309 'Lowry Aug. 28, 1923 1,538,584 Owen e't al. May 19, 1925 1,645,726 Vaughan Oct. 18, 1927 1,952,200 l lammang et a1. 'Mar. 27, 1934 "2,220,816 Gladics Nov. 5, 1940 2,243,835 Brunner -June 3, 1941 2,264,926 York Dec. 2, 1941 2,285,680 Roesen June 9, 1942 2,287,848 Wessl June 30, 1942 -2,29 7;-7'39 Blackley Oct. 6, 1942 2333, 286 'Wessel Nov. 2, 1943 2;362;82-3 'Hubell Nov. 14, 1944 

